U.S. patent number 4,606,181 [Application Number 06/466,562] was granted by the patent office on 1986-08-19 for method and apparatus for producing spun yarns of various constructions.
This patent grant is currently assigned to Wool Research Organisation of New Zealand (Inc.). Invention is credited to James Bedford, James Lappage.
United States Patent |
4,606,181 |
Lappage , et al. |
August 19, 1986 |
Method and apparatus for producing spun yarns of various
constructions
Abstract
A method and apparatus for producing spun yarns of various
constructions which includes separating a potentially highly
productive drafting stage from a spinning process and thereafter by
the use of an apparatus which can be used to spin and ply two yarns
while inserting an amount of twist of one sense into each yarn
while concurrently plying those yarns with an equal amount of twist
of the opposite sense. The apparatus can also be used to spin
singles yarns while concurrently inserting twist into that yarn in
a two-for-one mode. The yarns can be two twistless staple yarns or
a singles yarn which is spun and plied with a two-fold yarn to
produce a three-fold yarn structure. The twist in the three singles
components of the three-fold yarn structure can be equal in
magnitude and sense while the plying twist between the three
singles yarns can be equal in magnitude and opposite in sense to
the twist in the singles yarns. The method can produce yarns in
which the singles and plying twist senses can be twist-on-twist,
twist-against-twist, or a combination of these geometries. The raw
material supplied to the apparatus can be packages of twistless
yarns such as the slubbings produced on a woollen carding machine,
or twistless yarns such as those in which fibre cohesion is
achieved by means of a weak adhesive or by consolidating the fibres
in a rubbing process. The apparatus can be used to perform the
function of a conventional two-for-one twisting machine or to
combine conventionally spun yarns into various complex structures
while simultaneously modifying their individual twists in the
initial state.
Inventors: |
Lappage; James (Southbridge,
NZ), Bedford; James (Christchurch, NZ) |
Assignee: |
Wool Research Organisation of New
Zealand (Inc.) (Canterbury, NZ)
|
Family
ID: |
19919879 |
Appl.
No.: |
06/466,562 |
Filed: |
February 15, 1983 |
Foreign Application Priority Data
Current U.S.
Class: |
57/58.38;
57/58.36; 57/58.86; 57/328; 57/58.3; 57/58.59; 57/315 |
Current CPC
Class: |
D02G
3/285 (20130101) |
Current International
Class: |
D02G
3/26 (20060101); D02G 3/28 (20060101); D02G
003/38 (); D01H 001/10 (); D01H 005/28 (); D01H
007/86 () |
Field of
Search: |
;57/58.3-58.38,58.39-58.63,58.83,58.86,315,328 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Petrakes; John
Attorney, Agent or Firm: Watson, Cole, Grindle &
Watson
Claims
What we do claim and desire to obtain by Letters Patent of the
United States is:
1. A method of producing in a continuous operation of spun and
plied or cabled yarn, the method including the steps of:
supporting a first package of raw material within a balloon in a
running yarn;
supporting a second package of raw material spaced from the first
package;
withdrawing both ends of the material from their respective
packages under controlled and constant low tensions;
guiding and ducting the raw materials from their respective
packages to a means for forming a balloon in a running yarn;
simultaneously spinning and plying the running yarns to produce a
spun and plied or cabled yarn; and
drafting the spun and plied or cabled yarn in a drafting zone with
the temporary insertion of false twist before the yarn is delivered
to a take-up station.
2. A method as claimed in claim 1 including delivering the spun
yarn to a take-up station during which it is drafted in a drafting
zone immediately prior ro being wound at the take-up station.
3. A method as claimed in claim 2 which includes temporarily
modifying the twist in the yarn within the drafting zone.
4. A method as claimed in claim 1 wherein two-fold yarn is produced
in a single stage process.
5. A method as claimed in claim 1 wherein multiply yarns and cables
having up to four component strands are produced in a two-stage
process.
6. A method as claimed in claim 1 wherein multiply yarns and cables
having more than four component strands are produced in a
multistage process.
7. A method of producing in a continuous operation a spun singles
yarn, the method including the steps of:
supporting a package of raw material within a balloon in a running
yarn;
withdrawing the end of the raw material from the package under
controlled and constant low tension;
guiding and ducting the raw material from the package to a means
for forming the balloon in a running yarn;
spinning by two-for-one twist insertion the raw material to produce
a spun singles yarn; and
drafting the spun yarn in a drafting zone with the temporary
insertion of false twist before the yarn is delivered to a take-up
station.
8. A method as claimed in claim 7 including delivering the spun
yarn from the drafting zone to a take-up station.
9. A method as claimed in claim 8 which includes temporarily
modifying the twist in the yarn within the drafting zone.
10. An apparatus for producing in a continuous operation spun and
plied or cabled yarn, the apparatus including:
a rotating member for forming a balloon in a running yarn
comprising a hollow spindle having a cylindrical rotor for
supporting said balloon;
first and second supports for packages of raw material respectively
located within the balloon and outside the balloon;
guides and tensioning devices for withdrawing ends of raw material
from the supply packages under controlled and constant low
tensions; and
further guides and rotating co-operating rollers for effecting
delivery, drafting and winding of a yarn from said raw
materials.
11. Apparatus as claimed in claim 10 wherein the cylindrical rotor
includes a passageway extending therethrough which connects the
bore of the spindle with an egress at the top of the rotor, the
egress being situated close to an ingress in the rotor wall which
also connects to the passageway.
12. An apparatus as claimed in claim 10 wherein the rotating member
is a disc mounted on a hollow spindle, the disc being penetrated
diametrically by a passageway which interconnects with the bore of
the spindle, the disc having an inlet to the passageway which also
interconnects with the bore in the spindle.
13. An apparatus as claimed in claim 12 including means for
delivering the spun yarn to a take-up station, said means causing
the spun yarn to be drafted in a drafting zone.
14. An apparatus as claimed in claim 13 including means for
temporarily modifying the twist in the drafting zone.
15. An apparatus as claimed in claim 10 wherein a second cylinder
is supported coaxially within the cylindrical rotor and supported
on the spindle on a bearing such that the second cylinder can be
stationary whilst the spindle and rotor rotate, the second cylinder
having close to its upper rim a yarn take-off means.
16. An apparatus as claimed in claim 15 wherein the second cylinder
has a central mandrel therewithin which supports on a low friction
bearing the support for the first yarn package.
17. An apparatus as claimed in claim 16 wherein said central
mandrel has a narrowed portion at the top thereof, and wherein a
capstan is mounted on said narrowed portion, said capstan mounting
the first yarn guide.
18. An apparatus as claimed in claim 17 wherein a rail supporting
the spindle also supports a third stationary guard cylinder which
is coaxial with the spindle and second cylinder.
19. An apparatus as claimed in claim 10 wherein a second cylinder
is supported coaxially with and on the spindle on a bearing such
that the second cylinder can be stationary whilst the spindle
rotates, the second cylinder having a central mandrel therewithin
which supports on a low friction bearing the support for the first
yarn package, the mandrel having a narrowed portion on the top
thereof which supports via a bearing a flyer arm coaxially with
which is mounted the first yarn guide.
20. An apparatus as claimed in claim 10 in which all twisting
functions are carried out simultaneously by a single spindle.
21. An apparatus for producing in a continuous operation a spun
singles yarn, the apparatus including:
a support for a package of staple raw material;
a rotating member for forming a balloon in a running yarn;
a means for supporting said balloon so as to reduce to a minimum
the tensions and stresses arising in the yarn;
a guide and tensioning device for withdrawing the end of the raw
material from the package under controlled and constant low
tension; and
further guides and rotating co-operating rollers for effecting
delivery, drafting and winding of a yarn from said raw
material.
22. An apparatus as claimed in claim 21 wherein the cylinder and
rotor is penetrated by a passageway which connects the bore of the
spindle with an egress at the top of the rotor, the egress being
situated close to an ingress in the rotor wall which also connects
to the passageway.
23. An apparatus as claimed in claim 21 wherein the rotating member
is a disc mounted on a hollow spindle, the disc being penetrated
diametrically by a passageway which interconnects with the bore of
the spindle, the disc having an inlet to the passageway which also
interconnects with the bore in the spindle.
24. An apparatus as claimed in claim 23 including means for
delivering the spun yarn to a take-up station, said means causing
the spun yarn to be drafted in a drafting zone.
25. An apparatus as claimed in claim 24 including means for
temporarily modifying the twist in the drafting zone.
26. An apparatus as claimed in claim 21 wherein a second cylinder
is supported coaxially within the cylindrical rotor and supported
on the spindle on a bearing such that the second cylinder can be
stationary whilst the spindle and rotor rotate, the second cylinder
having close to its upper rim the yarn take-off means.
27. An apparatus as claimed in claim 6 wherein the second cylinder
has a central mandrel therewithin which supports on a low friction
bearing the support for the first yarn package.
28. An apparatus as claimed in claim 27 wherein said central
mandrel has a narrowed portion at the top thereof, and wherein a
capstan is mounted on said narrowed portion, said capstan mounting
the first yarn guide.
29. An apparatus as claimed in claim 28 wherein a rail supporting
the spindle also supports a third stationary guard cylinder which
is coaxial with the spindle and second cylinder.
30. An apparatus as claimed in claim 21 wherein a second cylinder
is supported coaxially with and on the spindle on a bearing such
that the second cylinder can be stationary whilst the spindle
rotates, the second cylinder having a central mandrel therewithin
which supports on a low friction bearing the support for the first
yarn package, the mandrel having a narrowed portion on the top
thereof which supports via a bearing a flyer arm coaxially with
which is mounted the first yarn guide.
Description
FIELD OF THE INVENTION
The present invention relates generally to the manufacture of spun
yarns, string, cords and other continuous thread-like materials.
More particularly, the present invention relates to a modified
processing system and apparatus for the production of a wide
variety of yarn structures, including singles yarns, plied yarns
and cabled yarns.
DESCRIPTION OF THE PRIOR ART
In conventional yarn making practice singles yarns are spun and
used as basic building blocks in the manufacture of the more
complex yarn structures. Prior to the spinning process, fibres,
which can be of natural or synthetic origin, are prepared on a
processing line which can include one or more of the steps of
carding, gilling, combing, drawing and roving. The prepared
material is then creeled in packages in a spinning frame where it
is subjected first to a draft, or attenuation, by which the linear
density is reduced to a required level, and is then twisted with an
amount of twist which depends upon the weight of the yarn and its
intended use. The spinning operation is thus normally carried out
on a machine such as a ringframe, a cap-frame or a flyer-frame, in
which the rotation of a spindle serves to both insert twist into
the yarn and to wind the yarn onto a package carried on the
spindle. Alternatively, the operation can be carried out on an
open-end spinning machine on which twist is inserted into the yarn
by rotating the forming yarn tail at a discontinuity in the supply
of fibres, and in which the yarn is wound onto a package which is
rotated solely for the purpose of winding.
In the manufacture of plied yarns, for example, a two-fold yarn,
singles yarns are creeled onto a twisting machine such as a
ring-twister, there being two singles yarns creeled for each
spindle of the twisting machine. The singles yarns are delivered
together at a constant speed and are twisted together and wound
onto a package by the rotation of the spindle. Alternatively, two
singles yarns can be wound together into a single package which is
creeled on a ring-twister, or can be used on a two-for-one twisting
machine. In the two-for-one twisting machine twist is inserted by
continuously looping the yarn around the supply, such that two
turns of twist are inserted between the two singles yarns for each
revolution of the spindle. The plied yarn so formed is then wound
into a package, which is rotated solely for the purpose of
winding.
Conventional processing lines have several drawbacks or
disadvantages which arise from the methods of processing and the
way these are organized in sequence. In the spinning process it has
in the past been found advantageous to include a drafting step as
part of the spinning function, particularly in those processing
routes where high draft ratios can be used. This, however, limits
the methods that can be used to insert twist into the yarn, and the
twisting action imposes an overall limitation on the productivity
of the process. In open-end spinning twist can be inserted into the
yarn at considerably higher rates, but open-end spun yarns have
been found to suffer from significant deficiencies of structure,
such that their use has become limited. Also, in spinning machines
of the ring and spindle type the size of the package that can be
made is limited by the gauge of the machine and the spindle speed
at which it is desired to operate.
In U.S. Pat. Nos. 3,820,316 (Clarkson) and 4,034,544 (Clarkson) are
described methods and apparatus for producing continuous filament
or spun staple yarns in which the plied yarns are subjected to heat
while tension in the yarn is relaxed, after which it is cooled and
dried to enable the yarn to be twist set in a bulked condition. The
objects of and the teachings of both these patents relate to the
manufacture of carpet yarns which optimize the development of bulk
and dyeability in plied yarns by twist setting the yarn in the
presence of either dry or moist heat under relaxed tension. These
patents do not describe or relate to the production of a variety of
yarns by modifying a yarn processing system and apparatus to form a
wide variety of yarn structures, including singles yarns, plied
yarns and cabled yarns.
A further disadvantage of conventional processes lies in the need
to provide separate machines of different design for the purpose of
producing plied yarns. These machines can be substantially similar
to spinning machines but without having means to draft the material
supplied to it. The function of the plying machine is thus limited
to the manufacture of plied yarns, and those machines of the ring
and spindle type are further limited in the method of twist
insertion and the size of the package which can be produced. The
two-for-one twisting machine is less limited in package size, but
by virtue of design its function is limited to that of plying.
Accordingly, it is a primary object of the present invention to
provide a method and apparatus for producing a wide variety of yarn
structures in a manner which avoids many of the disadvantages of
the conventional processes and which provides economies of
manufacture.
It is another object of the present invention to provide an
apparatus which has the versatility to produce singles, plied or
cabled yarns as are from time-to-time required, without the
necessity of effecting extensive adjustments to the apparatus.
It is a further object of the present invention to provide a method
of processing by which all the advantages of the novel apparatus
can be exploited.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, there is provided
a method of producing two-fold yarns in one continuous operation
which includes separating a potentially highly productive drafting
stage from a spinning process, and thereafter, using an apparatus
which can be used to spin and ply two twistless staple yarns,
inserting an amount of twist of one sense into each singles yarns
whilst concurrently plying those yarns with an equal amount of
twist of the opposite sense.
According to a second aspect of the present invention, there is
provided a method of producing spun yarn which includes separating
a potentially highly productive drafting stage from a spinning
process, using an apparatus which can be used to spin singles yarns
whilst concurrently inserting twist into that yarn in a two-for-one
mode.
According to a third aspect of the present invention, there is
provided a method of producing spun yarn which includes separating
a potentially highly productive drafting stage from a spinning
process, using an apparatus which can be used to produce a singles
yarn whilst concurrently plying it with a two-fold yarn to produce
a three-fold yarn structure. In the third aspect, the twist in the
three singles components of the three-fold yarn structure can be
equal in magnitude and sense whilst the plying twist between the
three singles yarns can be equal in magnitude and opposite in sense
to the twist in the singles yarns.
According to a fourth aspect of the present invention, there is
provided a method of producing twisted yarn constructions using an
apparatus which can be used to combine various existing singles or
plied yarn structures to form yarns of higher complexity, such as
fresco yarns and cables.
The method can be used to produce plied yarns in which the singles
and plying twist senses can be twist-on-twist, twist-against-twist,
or any combinations of those geometries.
The apparatus is supplied with raw material comprising packages of
twistless yarns such as the slubbings produced on a woollen carding
machine, or twistless yarns such as those in which fibre cohesion
is achieved by means of a weak adhesive or by consolidating the
fibres in a rubbing process.
The apparatus according to the present invention can also be used
to perform the function of a conventional two-for-one twisting
machine or to combine conventionally spun yarns into various
complex structures whilst simultaneously modifying their individual
twists in the initial state.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more clearly understood with reference to the
examples described with reference to the accompanying drawings,
which are given by way of example only, and in which:
FIG. 1 is a schematic diagram of an apparatus according to a
preferred embodiment of the present invention, showing its use for
the production of two-fold yarn;
FIG. 2 is a schematic diagram of part of an apparatus according to
a preferred embodiment of the invention, showing its use of the
production of singles yarns;
FIG. 3 is a schematic diagram of an alternative spindle design,
showing also an alternative method of delivering yarn from the
supply package; and
FIG. 4 is a enlarged view of an alternative type of apparatus which
can be used for yarn take-off from the supply package, and means of
controlling the take-off tension.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, the apparatus according to a preferred
embodiment of the invention comprises a hollow spindle 1, supported
by a bearing 2 in a rail 3, and has a pulley 4 by which it is
driven by a drive motor (not shown). A rotor consisting of a
cylinder 5 carried on top of, and which can form an integral part
of, spindle 1, is penetrated by a passageway or tube 6 which
interconnects with the bore 7 in the spindle 1. The passageway 6 in
the cylinder 5 has an egress 8 at the top of the cylinder 5,
situated closely to an ingress 9 in the cylinder wall, and which
also connect with the passageway 6. On top of the spindle 1 and
within the cylinder 5, a second cylinder 10 is supported on a
bearing 11, such that cylinder 10 can be stationary whilst the
spindle 1 and its associated cylinder 5 are rotating. Cylinder 10
has magnets 15 and a yarn guide 33 fixed close to its upper rim.
Cylinder 5 can be surrounded by a third, stationary cylinder 12
which forms a guard around cylinder 5, and is securely attached to
the rail 3. On top of cylinder 12 is carried a partial annulus 13,
which in turn carries magnets 14, equal in number and of opposite
polarity to magnets 15. Reaction between magnets 14 and 15 provides
force of sufficient moment to overcome the frictional forces
transmitted by the bearing 11 and windage on the surface of
cylinder 10 occasioned by the rotation of cylinder 5 and spindle 1.
Within the cylinder 10 is a central mandrel which comprises a fixed
inner part 16 supporting an outer part 17 which is free to rotate
on a low friction bearing 18. A disc 19 is attached to the lower
end of the mandrel part 17, together with which it supports a
package of twistless yarn 20. Mandrel part 16 has a narrowed
portion at the top which supports a capstan 22 having a yarn guide
at its top. Capstan 22 is a push fit on mandrel part 16 such that
it can be rotated relative to part 16 by firm finger torque. A yarn
guide 23 is fixed above the capstan 22 on the common axis of the
spindle 1 and mandrel part 16, and a pair of rollers 24 is provided
to control the rate at which yarn is delivered. A second package 25
of twistless yarn is located below the hollow spindle 1 and is
supported by a mandrel 26 and capstan, of similar design to mandrel
16,17, on a rail 27. A second pair of rollers 28 can be provided so
that yarn can be drafted in the zone between rollers 24 and rollers
28. A winding mechanism 29 is provided to package the plied yarn.
Whilst being drafted between the rollers 24 and rollers 28, control
of the fibres within the yarn is achieved by virtue of the twist
within the yarn, in a similar manner to a method of achieving fibre
control during drafting in the conventional woollen spinning
process. By this means, draft ratios of up to 1.5 to 1 are
possible, and in order to optimize the degree of fibre control in
the drafting zone, a false twisting mechanism 36 can be included to
temporarily modify the twist in the yarn within the drafting zone
in a manner similar to that commonly used in the conventional
woollen spinning process. In the present case, however, the false
twisting mechanism can be used to temporarily remove or reduce the
twist in the yarn rather than temporarily increase the twist in the
yarn, as is the case in conventional woollen spinning.
In operation, when it is required to produce a two-fold yarn, yarn
31 from the supply package 25 is withdrawn via yarn guide 30 and
the capstan on top of mandrel 26, and is then taken through the
bore 7 in spindle 1 and the passageway 6 in the rotor 5 to egress
at 8. Yarn 32 from the supply 20 is withdrawn via yarn guide 33 and
the yarn guide in the capstan 22 to the ingress 9 in the wall of
cylinder 5 where it is converged with yarn 31. Withdrawal of yarns
31 and 32 from their respective supply packages 25 and 20 sets up a
low tension in the yarns between their respective supply packages
and tension control capstans, this tension being just sufficient to
pull the supply packages and support mandrels, causing them to
rotate on the low friction bearings 18, and so deliver yarn by
unwinding. Yarns 31 and 32 are then taken together via rollers 24
and 28 to the yarn winding station 29. It will be appreciated that
yarn 31 is ballooned around supply package 20 by virtue of the
rotation of the spindle/cylinder 1,5 rotor assembly, thereby
generating one turn of real twist between the two yarns 31 and 32
for each revolution of the rotor. It will also be appreciated that,
in the absence of yarn 32, the action of the rotor on yarn 31 is
simply that of a false twisting mechanism, one turn of twist of one
sense being generated in yarn 31 between the hollow spindle and the
capstan of mandrel 26, and one turn of twist of the opposite sense
being generated in yarn 31 between the egress 8 and the yarn guide
23 for each revolution of the rotor. These twists are thus mutually
cancelling, and if the apparatus were to be run with only the
supply package 25 of twistless yarn, then the yarn wound at the
winding station 29 would also be twistless. Similarly, in the
absence of yarn 31, false twist is generated in yarn 32 by virtue
of the rotation of the rotor, one turn of twist of one sense being
generated between the capstan 22 and yarn ingress 9, and one turn
of twist of the opposite sense being generated between the egress 8
and the yarn guide 23 for each revolution of the rotor. A yarn
guide 35 is provided below the spindle station for use when
spinning singles yarn.
In practice, when yarns 31 and 32 are processed together, real
plying twist is generated between them by virtue of yarn 31 being
ballooned around the supply package 20. This plying twist is
inserted at the yarn guide 23 to form a plied yarn 34 and is
carried downstream with the yarn 34 from that point. In practice it
has been found that by virtue of the plying torque generated at the
yarn guide 23, the plying twist also tends to run against the flow
of yarn some way towards the yarn egress 8. From the yarn guide 23
the plied yarn 34 is delivered via the take-off rollers 24 and the
drafting rollers 28 to the yarn take-up station 29. If this plied
yarn is now examined and the plying twist is removed by untwisting,
it will be found that the two singles yarn components both contain
twists which are equal in magnitude and sense, and are equal in
magnitude but of opposite sense to the plying twist between them.
This yarn structure is thus identical with a two-fold yarn of
conventional manufacture in which firstly singles yarns are spun
having X twists per unit length of Z twist, and two such singles
yarn are plied together with X twists per unit length of S
twist.
Referring now to FIG. 2, when it is desired to produce a singles
yarn the lower supply package is not required and only the supply
package 20 is creeled into the machine. When spinning singles yarn
the flow of yarn through the passageway 6 in the wall of the rotor
5 is reversed so that yarn from supply package 20 is taken via yarn
guide 33 and the yarn tensioning capstan 22 to the ingress 9 in the
rotor wall, and via the passageway 6 to the bore 7 in spindle 1.
From the bottom of spindle 1 the singles yarn is then taken via
yarn guide 35 to the take-off rollers 24, the drafting rollers 28
and the yarn take-up station 29. By virtue of the rotation of the
rotor, yarn 32 is caused to balloon around its supply package 20
between the top of capstan 22 and the axis of spindle 1. For each
revolution of the balloon, one turn of twist is inserted into yarn
32 as it emerges from the capstan 22, and a second turn of twist,
of the same sense as the first turn, is inserted into yarn 32
within the hollow spindle. The apparatus is then operating in a
two-for-one mode of twist insertion.
An alternative design of apparatus which can be preferred for the
production of some yarn types is illustrated schematically in FIG.
3 and comprises a hollow spindle 1 which is supported, for example,
in a non-vertical attitude on the axis XX.sup.1 by a bearing 2 in a
rail 3, and has a pulley 4 by which it is driven by a drive motor
(not shown), and a disc 5 carried on top of, and forming an
integral part of, spindle 1 is penetrated by a passageway or tube 6
which interconnects with the bore 7 in the spindle 1. On top of the
spindle/disc assembly a cylinder 10 is supported by a bearing 11
and such that cylinder 10 can be stationary whilst the spindle/disc
assembly is rotating. Within the cylinder 10 is a central mandrel
16 which supports a package of twistless yarn 20. A flyer arm 37,
integral with a capstan 22 mounted on top of, and co-axially with,
the mandrel 16 is free to rotate about its axis, and assists in
delivering yarn from the package 20 and in controlling the yarn
tension. A yarn guide 23 is fixed above the capstan 22 on the
common axis XX.sup.1, and a pair of rollers 24 is provided to
control the rate at which yarn is delivered. A counterweight 38 is
eccentrically positioned in cylinder 10 so as to deter rotation of
cylinder 10 and its contents by virtue of gravitational force.
Alternatively, rotation of cylinder 10 can be deterred by magnetic
means. A balloon control ring or shield 12, can be provided
surrounding the ballon formation area to provide improved control
of the yarn balloon during high-speed spinning. A yarn guide 35 is
provided below the spindle station for use when spinning singles
yarn. A second yarn supply package (not shown) is provided below
the spindle, together with its associated flyer arm and support
mandrel, and drafting rollers and a yarntake-up station can be
provided as previously described and illustrated in FIG. 1.
In operation, and when producing singles yarn, the lower supply
package is not required, and yarn 32 from package 20 is taken
through the balloon zone to an inlet to the passageway 6 in the
disc/spindle assembly 5,1. Yarn 32 is then withdrawn down through
the hollow spindle 1 and is delivered via guide 35 to the drafting
zone and the yarn winding station. By virtue of the rotation of the
spindle/disc assembly 1,5, yarn 32 is caused to balloon around its
supply package 20 between the guide on top of the capstan 22 and
the ingress to the disc 5. For each revolution of the balloon one
turn of twist is inserted into the yarn as it emerges from the
capstan 22, and a second turn is inserted into the yarn 32 within
the hollow spindle. In FIG. 3 the apparatus is shown producing
two-fold yarn in which case the second yarn supply package is
required. Yarn 32 from the supply package 20 is taken first through
the balloon zone between the top of capstan 22 and the ingress to
the passageway to the disc 5, through the disc and then through a
second balloon stage between the egress from the disc 5 and the
yarn guide 23. Yarn 31 from the second supply is taken through the
hollow spindle to join with yarn 32 within the passageway 6 in the
disc 5. On emerging from the disc 5 in company with yarn 32, the
yarn 31 is also ballooned between the egress from disc 5 and the
yarn guide 23, to form a common balloon with yarn 32. By virtue of
the rotation of the spindle/disc assembly 1,5 yarn 32 is then
ballooned twice around its own supply package 20; and under this
circumstance for every revolution of the spindle/disc 1,5 assembly,
one turn of twist of one sense is inserted into yarn 32 as it
emerges from the top of capstan 22, and a second turn of twist of
the opposite sense is inserted into yarn 32 as it passes through
the yarn guide 23. These twists are thus mutually cancelling, and
if yarn 32 were to be processed in this way in the absence of any
other yarn, then the spindle would be acting as a false-twisting
device and downstream of the yarn guide 23 the twist in yarn 32
would be unchanged from its initial condition. Also, by virtue of
the rotation of the spindle/disc 1,5 assembly, one turn of twist of
one sense is inserted into yarn 31 along the axis of rotation and
within the bore 7 of spindle 1, and a second turn of twist of the
opposite sense is inserted into yarn 31 at the yarn guide 23. These
twists are again mutually cancelling, and if yarn 31 were to be
thus processed in the absence of any other yarn, then the spindle
would again be acting as a false twist device, and downstream of
yarn guide 23 the twist in yarn 31 would be unchanged from its
initial condition.
In practice, when yarns 32 and 31 are processed together, a real
plying twist is generated between them by virtue of yarn 31 being
ballooned around the supply package 20. This ply twist is inserted
between the two yarns at the yarn guide 23 to form a plied yarn 28
and is carried with the yarn 28 downstream from that point. In
practice, it has been found that by virtue of the plying torque
generated at the yarn guide 23, the plying twist also tends to run
against the flow of yarn some way into the balloon zone. From the
yarn guide 23 the plied yarn 28 can be delivered via the take-off
rollers 24 to a drafting zone and a yarn take-up station as
previously described and illustrated in FIG. 1.
The spinning action of this alternative design of spindle is
substantially the same as that previously described in relation to
FIG. 1, in that when a singles yarn is produced the yarn 32 is
caused to balloon continuously around its own supply package 20,
two turns of twist being inserted into yarn 32 for each rotation of
the spindle/disc assembly, and when a two-fold yarn is produced the
yarn 31 is continuously ballooned around the yarn supply package 20
such that real twist is generated between the singles yarns 32 and
31. Again, when spinning two-fold yarns, false twist is generated
in each of the singles yarns 32 and 31 between the point of
delivery from their respective capstan tension controls and the
yarn guide 23. Again, when producing two-fold yarn the plying twist
is generated at the yarn guide 23 and is carried downstream with
the yarn but also tends to run upstream towards the point at which
the two singles yarns 32 and 31 are first converged, by virtue of
the torque generated by the plying twist.
The spindle design illustrated in FIG. 1 offers the advantage that
the yarns are not subjected to the tensions imposed by ballooning
by virtue of the support provided to the balloon, or balloons, by
the cylinder 5. When producing singles yarn, the yarn 32 is thus
subjected only to the centrifugal force developed by the rotation
of the relatively short, unsupported length of yarn between the top
of the capstan 22 and the yarn ingress point 9, and by the
frictional drag on yarn 32 imposed by its passage through the yarn
passageways 6 and 7 plus the tension imposed at the capstan 22.
When producing two-fold yarns, the yarn 31 is subjected to the
forces of frictional drag by passage through the passageways 7 and
6, and the tension imposed by the capstan at its supply package,
the yarn 32 is subjected only to the centrifugal force due to
rotation of its unsupported length and the tension imposed by the
capstan 22, and the two-fold yarn structure 28 is subjected only to
the centrifugal forces due to rotation of that relatively short
length of yarn between the yarn egress point 8 and the yarn guide
23 plus the tensions existing in the two singles yarns at the yarn
egress point 8. The reduced forces thus imposed on a yarn during
spinning when the spindle design depicted in FIG. 1 is used make it
possible to process at significantly increased spindle speeds and
also to manufacture yarn of significantly reduced twist.
It will be evident that, when producing two-fold yarns, it is
normally preferred to subject the two singles yarns to equal
tensions at the point of, and at the time of, plying. The differing
paths followed by the two singles yarns 31 and 32 according to both
of the spindle designs shown in FIGS. 1 and 3, can be expected to
produce differing tensions in the two singles yarns 31 and 32 at
the point of plying. In order to overcome this circumstance it is
necessary to provide means for adjusting the overall tension in one
or both of the single yarns 31 and 32 during transport from their
respective supply packages and the point at which they are
converged, i.e., yarn egress point 8. Tension control in the
singles yarns is effected according to the present invention by
means of an adjustable capstan device around which the yarn is
wrapped to provide frictional drag, and incorporated as part of the
supports for the two supply packages.
FIG. 4 shows an enlarged view of a flyer arm device such as that
depicted in FIG. 3. The flyer arm rotates on a shaft 38 which is
supported in a bearing 39 fixed in the top of the mandrel 16
carrying the yarn supply package 20. Mounted on, and co-axial with
the shaft 38, is a capstan of circular section which is divided
into two parts 40 and 41. Fixed to component 41 is the arm of the
flyer 37, which has at one end a yarn guide 42 and at its other end
a counterbalancing weight 43. The flyer arm 37 is rigidly fixed to
the capstan component 41 and rotates with it. The second capstan
component 40 has near its top a yarn guide consisting of a yarn
ingress 44 in the wall of the capstan which connects with a yarn
egress 45 in the top of the capstan and on the axis of rotation of
the flyer arm. Yarn 32 from the supply package 20 is delivered via
the yarn guide 42 of arm 37 to wrap the capstan component 40 before
being threaded through the yarn guide comprising the ingress 44 and
the egress 45 in the top of the capstan. Tension is developed in
the yarn depending upon the total angle by which it wraps the
capstan. The two parts 40 and 41 of the capstan are so constructed
and joined together at 46 that component 40 can be rotated relative
to component 41, about their common axis, and thus to vary the
total angle of wrap of the yarn 32 in a continuous manner. A degree
of friction is achieved between the two capstan components 40 and
41 such that their mutually relative positions will not change
except by positive adjustment by a deliberate force. By this means
the total overall tensions developed in the two singles yarns 31
and 32, can be separately adjusted to achieve equality of singles
yarn tension at the point of plying. Further to this, it is also
possible to arrange the singles yarns tensions to be unequal when
it is required to produce a two-fold or other plied yarns having a
fancy spiral effect.
It will be understood that yarns of more complexity than a two-fold
structure can be produced if one or both of the supply packages 20
and 25 is replaced by a spun singles yarn embodying real twist, a
two-fold yarn, or yarn of other structure. By this means it is
possible to build up multiply yarns and cables of any desired
construction. For example, if in the first instance a two-fold yarn
is produced, starting with two supply packages 20 and 25 comprising
singles, twistless yarns, to a linear density of R600/2 tex, and
having three twists Z per inch in each ply and three twists S per
inch between the two plys, and in the second instance this two-fold
yarn is creeled in place of supply package 20 and is further plied
with singles twistless yarn of linear density 300 tex from supply
package 25, with three twist per inch S, the resulting yarn will be
a three-fold construction of linear density R900/3 tex having three
twists per inch Z in each of the three component singles yarns, and
three twists per inch S plying twist between the three component
singles yarns, and three twists per inch S plying twist between the
three component singles yarns. If both of the supply packages 11
and 18 are replaced with two-fold yarn of linear density R600/2 tex
having three twists per inch Z, in each ply and three twists per
inch S between the two plies, and these two, two-fold yarns are
then plied together with three twists per inch S then a four-fold
yarn of linear density R1200/4 tex is made having three twists per
inch Z, in each of the four plies, and three twists per inch S
plying twist between the four plies. If, however, these two
two-fold yarns are plied together with three twists per inch Z
twist, for example, by reversing the direction of rotation of the
spindle, then a cabled yarn structure denoted as R1200/2/2 tex is
made having three twists per inch Z in each of the four component
singles yarns, six twists per inch S plying twist in each of the
two two-fold yarns, and three twists per inch Z cabling twist
between the two two-fold yarns. Many other yarn structures can be
built up in this way as will become evident from further
consideration of the multiple twisting and plying actions of the
spindle according to the present invention.
It will be appreciated that a raw material supply package of
twistless yarn exists and is widely used in the textile industry
which is suitable for use in the yarn manufacturing system
according to the present invention, this being the slubbing
produced by the woollen carding operation. Woollen processed
slubbing is prepared on the woollen carding machine in ribbon form,
which ribbon is then consolidated by rubbing between reciprocating
aprons prior to being wound on the carding machine into spools
comprising a multiplicity of cheeses of separate ends of slubbing.
These spools are normally creeled complete at a spinning machine
such as a ringframe or a mule, but the spool may also be
deconsolidated into individual cheeses which are creeled separately
at the spinning machine. The conventional cheese of woollen
slubbing is a supply package of twistless yarn eminently suitable
for use in a spinning machine according to the present invention.
In conventional spinning, woollen slubbing is normally subjected to
a low draft step of ratio less than 2:1, prior to the insertion of
real twist into the yarn, which draft is effected against a false
twist as a means of gaining fibre control. The use of a low draft
is desirable as a means of improving the yarn evenness and making
minor adjustments to the count of the yarn. In the process
according to the present invention the drafting step can be
effected after the insertion of real twist into the yarn, and to
assist this drafting process that real twist may be temporarily
modified by the application of a false twist in a manner similar to
the conventional process.
In a further known process packages of twistless yarn can be
prepared in long draft processes such as the worsted and
semi-worsted systems, by means of the continental rubbing finisher,
a machine designed primarily for the manufacture of twistless
worsted rovings. In this machine worsted tops or slivers are first
subjected to draft ratios of up to 30:1 or more in order to
attenuate the slivers to a desired linear density, and are then
rubbed by reciprocating aprons to consolidate the structure, and
are then wound into individual cheeses of twistless roving. It has
been found practical by means such as this to provide packages of
twistless yarn suitable for the production according to the present
invention of many yarn structures.
It will be understood that the foregoing descriptions of preferred
embodiments of the present invention, and the operational features
and techniques are given by way of example only, and that a number
of variations and modifications are possible without departing from
the scope and spirit of the appended claims.
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